A binder-free dry coating process for high sulfur loading cathodes of Li–S batteries: A proof-of-concept

A promising candidate for next-generation energy storage is the lithium-sulfur battery (LSB) due to its high capacity and low-cost active material (sulfur). However, the practical application of LSBs is challenged by poor cycling life and low sulfur loading. Herein, a proof-of-concept for manufactur...

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Bibliographic Details
Published in:	Journal of power sources Vol. 587; p. 233675
Main Authors:	Horst, Marcella, Burmeister, Julian K., Abdollahifar, Mozaffar, Pillitteri, Salavatore, Kwade, Arno
Format:	Journal Article
Language:	English
Published:	Elsevier B.V 15-12-2023
Subjects:	Binder-free electrodes Dry coating Lithium-sulfur batteries Sulfur carbon composites Thermogravimetric analysis Lithium-sulfur batteries Thermogravimetric analysis Dry coating Sulfur carbon composites Binder-free electrodes
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Summary:	A promising candidate for next-generation energy storage is the lithium-sulfur battery (LSB) due to its high capacity and low-cost active material (sulfur). However, the practical application of LSBs is challenged by poor cycling life and low sulfur loading. Herein, a proof-of-concept for manufacturing high load electrodes with a low-cost dry (solvent-free) coating process with a reduced carbon footprint is introduced and investigated. This process is often based on fluoropolymer-based binder additives with health and environmental concerns. Therefore, this study presents the concept of a binder-free dry coating process using sulfur/carbon black (S/CB) composites derived from a straight-forward dispersive mixing process. The electrodes are fabricated by a hot-pressing process, taking advantage of sulfur melting into a carbon matrix. To determine the process-structure-property relationships of the resulting powders, electrodes and cells, a novel structure determination by thermogravimetric analysis was used. Mixing time turns out to be an important factor, which has a significant effect on the electrode performance. The cells assembled with electrodes (⁓4.5 mgS cm−2) made from optimized powder mixtures showed a high specific capacity of about 800 mAh gS−1, and a relatively improved C-rate capability. [Display omitted] •Proof-of-concept for manufacturing electrodes with high mass load is introduced.•Binder-free electrodes are fabricated via a dry coating process.•Thermogravimetric analysis has been used to evaluate the electrode structure.•Process-structure-property relationships of powders and electrodes are discussed.•Mixing time is a key factor for producing a high-performance electrode.
ISSN:	0378-7753 1873-2755
DOI:	10.1016/j.jpowsour.2023.233675